0439504 JOHNSON CARBURETOR REPAIR KIT

level
Fuel supply
Starting aids (if applicable)
Cranking speed
Shutdown switch
Active engine shutdown
Electrical connectors
Circuit breakers
Personality module
Engine speed/timing sensor
Injector solenoid
Air shutoff (if applicable)Perform the following checks:
Measure the voltage at the connector of the Electronic Control Module (ECM). If the ECM is not receiving battery voltage, the ECM will not power up. Refer to the diagnostic functional test Troubleshooting, "Electrical Power Supply".
Visually check the fuel level. If necessary, add fuel. Ensure the proper operation of the jacket water heater. Repair the jacket water heater and/or replace the jacket water heater. Check for the presence of solidified fuel (wax).
Check the fuel system. Check fuel lines for the following problems: restrictions, collapse, pinched line and loose fittings. Repair the lines and/or replace the lines.
Check the fuel tank for foreign objects which may block the fuel supply. Check for air in the low pressure fuel supply system after you perform the following procedures:
Replacing the fuel filters
Working on the low pressure fuel supply circuit
Replacing fuel injectors
Purge air from the low pressure fuel supply circuit with the hand priming pump and by cranking the engine in 30 second cycles. After you crank the engine, stop for two minutes. This will allow the starting motor to cool. Loosen the vent plug for the fuel return line. The plug is located on the rear upper left side of the engine block. Hand prime the engine again if air in fuel continues. A sight glass in the low pressure supply line is helpful in diagnosing air in the fuel.
Check fuel quality. In temperatures below 0 °C (32 °F), check for solidified fuel (wax). Refer to Special Publication, SEBD0717, "Diesel Fuels And Your Engine". Check the fuel pressure while the engine is cranking. Check the fuel pressure at the filter. If the pressure is low, check for plugged fuel filters. If the fuel pressure is still low, check the following items: fuel transfer pump, fuel transfer pump coupling and fuel pressure regulating valve.
If equipped, check the operation of the ether starting aids. Replace the ether canister if the ether is low. Refer to the diagnostic functional test Troubleshooting, "Ether Injection System".
Check the cranking speed of the starter.
The shutdown switch should be in the OFF position. Connect the Caterpillar Electronic Technician (ET). Use Cat ET in order to verify the status of the shutdown switch. If the Cat ET will not communicate with the ECM, refer to the diagnostic procedure Troubleshooting, "Electronic Service Tool Will Not Communicate with ECM". When a shutdown occurs, the keyswitch must be turned to the OFF position. The keyswitch must then be turned to the ON position before the engine will start.
Use Cat ET to determine if any active shutdowns are present. If a Shutdown is "ACTIVE", determine the reason. After you correct the problem, turn the keyswitch to the OFF position for at least 15 seconds before you try to restart the engine.
Check for correct installation of the following components: ECM connectors J1/P1 and J2/P2, customer connector, connector for the engine speed/timing sensor and fuel injector connectors. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors".
The circuit breakers may exceed the trip point due to overheating. Check the circuit breakers on the machine. Reset the circuit breakers if the circuit breakers are tripped.
If the diagnostic code 253-02 is present, program with the correct flash file.
Crank the engine and observe the engine rpm on Cat ET. If engine rpm is 0, refer to the diagnostic functional test Troubleshooting, "Engine Speed/Timing Sensor".
Ensure that the timing reference gear is installed correctly. The engine will not start if the gear was installed backward. Check for proper orientation between the crankshaft and camshaft drive gears. Correct the orientation and/or replace the drive gear. Refer to Disassembly and Assembly Manual.
Perform the "Injector Solenoid Test". Verify that the ECM is energizing all the injector solenoids. Refer to the diagnostic functional test Troubleshooting, "Injector Solenoids".
Verify that both of the air shutoff valves are open and that both of the air shutoffs are in the starting position.
Check for a problem with the combustion system.